Performance Alloys Productsperformancealloys.net/misc/Catalog(newlyrevised).pdfof finish machined...

...World Wide Distributor Beryllium-Free CopperAlloys...Manufacturer of Standard & Custom Mold Components

N116 W18515 Morse Dr.Germantown, WI 53022

(262) 255-6662Fax (262) 255-3655

1-800-272-3031

Providing Industry with Technology, Products and Services Since 1987

E MAIL: [email protected] WEB SITE: www.performancealloys.net

Our primary focus is to help you improve part quality, mold productivity and overall performance with our Beryllium-Freecopper alloy materials & products.

Performance AlloysOur NEW MoldStar® Alloys & Precision Machining Capabilites

® is Proud to Introduce

MoldStar® 18, 21 & 22 Aluminum Bronze Alloys

MoldStar® 90 * in PLATE & Round Bar* MoldStar® 150 *(formerly PAS or Ampco 940)*

Performance Core Pins® Performance Sprue Bushings®

Performance Mold Products®

ATTENTION: We also offer molders and moldmakers the option of finish machined components at competitive prices, with on timedeliveries and unmatched quality. We are proud of the fact thatconsistently, year after year, our customers rate us at the highestlevels for our Quality, Service, Competitive Prices and ON TIMEDELIVERIES.

Feel free to request a quote for your CUSTOM ComponentsALWAYS CHECK OUR WEBSITE! www.performancealloys.net, for the LATEST Product Information & Technical UPDATES

We personally invite you to experience our exceptional level of quality and service.

CONTENTS

• COVER PAGE• INDEX• GENERAL INFORMATION, POLICIES and ACKNOWLEGEMENTS• PRODUCTS• MoldStar MATERIAL RECOMMENDATIONS• POPULAR MATERIAL COMPARISONS

MoldStar MATERIAL FOR PLASTIC FORMING AREAS• MoldStar 90 APPLICATION INFORMATION• MoldStar 90 AVAILABLE PLATE and BAR SIZES• MoldStar 150 APPLICATION INFORMATION• MoldStar 150 AVAILABLE PLATE and BAR SIZES

HOW WE STACK UP AGAINST THE COMPETITION

MoldStar BRONZES FOR WEAR APPLICATIONS• MoldStar 18 APPLICATION INFORMATION• MoldStar 18 SOLID ROUND BAR SIZES• MoldStar 18 RECTANGULAR SIZES• MoldStar 18 TUBE SIZES• MoldStar 21 APPLICATION INFORMATION• MoldStar 21 SOLID ROUND BAR SIZES• MoldStar 21 RECTANGULAR SIZES• MoldStar 22 APPLICATION INFORMATION and SIZES

HIGH CONDUCTIVITY COPPER ALLOY CORE PINS• PERFORMANCE CORE PIN APPLICATION INFORMATION• PERFORMANCE CORE PIN SPECIFICATION and SIZES• PERFORMANCE CORE PIN PRICING

HIGH CONDUCTIVITY SPRUE BUSHINGS• PERFORMANCE SPRUE BUSHING APPLICATION INFORMATION• PERFORMANCE SPRUE BUSHING SPECIFICATIONS and SIZES• PERFORMANCE SPRUE BUSHINGS for ABRASIVE RESINS5

ORDER FORMS AND PRINT MASTERS• MoldStar MATERIAL ORDER FORMS• CUSTOM COMPONENT ORDER INFORMATION• STANDARD STRAIGHT EJECTOR PIN SIZES• STANDARD STEP EJECTOR PIN SIZES• CUSTOM EJECTOR SLEEVE PRINTS• CUSTOM STEP PIN PRINTS• CUSTOM STRAIGHT PIN PRINTS

MISC. TECHNICAL DATA• SAWING INFORMATION• MACHINING INFORMATION• PLATING INFORMATION

WELDING INFORMATION• WELDING GUIDELINES• MoldStar WELDROD

GENERAL CONDITIONSWhile every effort is made to offer stable and competitive pricing, prices are subject to change withoutnotice. Previously quoted prices are subject to the term limits on a specific quotation. Because ofcircumstance beyond our control, product and supplier changes/substitutions are made from time to time.When such instances occur the material and products will meet at least the minimum published propertiesas outline in our promotional literature.

TERMSNet 30 days to established US businesses with acceptable credit history. We may from time to timeestablish credit limits or require partial or full prepayment before orders are shipped and/or processed.Payment terms for Non US businesses are typically due via wire transfer prior to shipment, or as arrangedprior to order placement.

DELIVERIESEvery effort is made to meet quoted ship dates, but may be subject to delays caused by fire, strike or othercauses beyond our control. We cannot be responsible for such delays or delays arising from transportationservice, nor damage sustained by goods after delivery to carrier.

RETURNED GOODS/ORDER CANCELLATIONSNo goods are returnable without prior approval and prepaid transportation. All returned items are subject toour inspection before credit is allowed/issued. Custom forged or non-standard sizes and shapes may benon-returnable. No goods are returnable later than 30 days after receipt of merchandise. Credit for returnedgoods will be based on re-saleable condition of returned item. Cancellation of an order after either verbal orwritten purchase order confirmation is subject to a cancellation/restocking charge. An order cancellationnotice must be in writing to us and delivered to our sales office to be considered cancelled. Finish orpartially finish machined components are non-returnable unless our work was not to original printspecifications..

DEFECTIVE MATERIALEvery effort is made in manufacturing, inspection and other parts of our processes to insure sound products.Even with our extensive process control and inspection, there can be metallurgical defects that goundiscovered. We deeply regret those situations and will gladly replace any piece or pieces of material thatprove to be metallurgically defective. We cannot warrant any material that has been welded, or subjected toheat treatments done by others. Liability for defective material is limited to replacement of that materialonly.

SUBJECT TO CHANGEWe reserve the right to make changes of any type without notice, obligation or liability.

TRADEMARK ACKNOWLEGDMENTSMoldStar as well as the word Mold accompanied by a Star symbol, Performance Core Pins andPerformance Sprue Bushings are all Registered Trademarks of Performance Alloys and Services, Inc.MoldMAX and proTHERM are Registered Trademarks of Brush Wellman Engineered Materials.MoldMATE and Ampco are Registered Trademarks of Ampco Metal Inc, and QC-7 is a RegisteredTrademark of Copper and Brass Sales.

Performance Alloys and Services, Inc.Performance Mold Products, Inc.

N116 W18515 Morse Dr.Germantown, Wisconsin 53022262-255-6662 or 800-272-3031

Fax:262-255-3655Email: [email protected]

WebSite: www.performancealloys.netAlways refer to our website for the most current product as well other information

ProductsQUALITY RAW

MATERIALSMoldStar® 90 & 150 for Cores and CavitiesOutperform Competitive Products!Our Beryllium-Free Copper Alloys have beenproven to be the material of choice for the BEST Performance in Injection & Blow Mold applicationsBeing Beryllium-Free means safe, economical,mechanical and environmental advantages.

SAFE TODAY, SAFE TOMORROW

MoldStar® 18, 21 & 22 Bronze AlloysOutlast those "other" Bronzes!MoldStar®Bronze materials for wear applicationprovide economical and performance advantagesover laminated products for wear plate, bushing &sleeves applications.

STANDARD MOLD COMPONENTS

PERFORMANCE CORE PINS®

Performance Alloys® offers a complete line of offthe shelf Performance Core Pins® in the bestBeryllium-Free materials.

PERFORMANCE SPRUE BUSHINGS®

Performance Alloys® has a Patented design onPerformance Sprue Bushings® which offers youfaster sprue cure rates to reduce mold cycles.Available in standard and custom sizes to matchyour needs, and a brand new carbide lined sprue forabrasive resins.

CALL with YOUR SPECIFIC APPLICATION

MoldStar® 90 @ 31 Rockwell "C"A Truly NEW Copper Alloy with the BEST Balance of HARDNESS & CONDUCTIVITY

Available in a broad range of sizes and forms

MoldStar® 150 @ 18-22 Rockwell "C"

Full Range of Sizes, Standard & Custom

MoldStar® 18, 21 & 22 Bronzes

PERFORMANCE CORE PINS ®The NEW STANDARD IN OFF THE SHELFHIGH CONDUCTIVITY COPPER ALLOYMOLD COMPONENTS


SPEED UP MOLDS WHERE THE SPRUE ISLIMITING OR CONTROLLING THE CYCLE


CARBIDE LINED (for abrasive resins)PLUS SPEEDS UP THE CYCLE BY DESIGN

EJECTOR PINS THRU HARD FOR DEMANDING MOLDS

PLUS COMPONENTS OF ALL TYPESMADE IN OUR FACILITY TO MEET YOURDEMANDING APPLICATIONS

PLUS: Machining Services OfferedPerformance Alloys® offers finished machine components to your specifications. Components can bemade from conductivity alloys or toolsteels. We can also supply complete with all popular hardness andrelease coatings. Short lead times and close tolerances are our Commitment to Excellence.

Shipping

Direct shipments can be arranged worldwide to almost anywhere.

CYCLE REDUCTIONS AND QUALITY IMPROVEMENTS ARE NOT JUST BUZZ WORDS FOR US, THEY ARE FACTS.

MoldStar ® Material Recommendations

150

MoldStar® Cu 96.4Ni 2.5Si 0.7

(PAS 940) Cr 0.4

Very high thermal conductivity,resistance to corrosion and wear,moderate hardness

Mold cores, cavities, spruebushings, hot runner systems,core pins, ejector pins, sleeves,blow pins

90MoldStar® Cu 89.0 (est)

Ni 7.5 (est) Other 3.5 (max.)

Excellent Balance of thermalconductivity, Hardness &corrosion resistance and wear

Mold inserts, thermal pins, moldcores, cavities, lifters, etc,

18

MoldStar® Cu 85.5Al 10.5Fe 3.5

(PAS 18) Other 0.5 (max.)

Good bearing qualities, resistanceto wear, abrasion, fatigue,deformation and corrosion

Slides, gibs, wear plates, moldlocking devices, sleeve bearings,guide pin bushings, guide rails

21

MoldStar® Cu 80.2 Al 12.8 Fe 4.5


Harder alloy with good bearingqualities, resistance to wear,abrasion, fatigue, deformation andcorrosion

Lifter blades, slides, gibs, wearplates, ejector sleeves andbushings, guide pin and leaderpin bushings

22

MoldStar® Cu 78.7Al 13.8 Fe 5.0


Harder alloy with good bearingqualities, resistance to wear,abrasion, fatigue, deformation andcorrosion

Ejector sleeves, lifter blades,thin wall applications, ejectorand core pins, guide pin andleader pin bushings, unscrewingmold components

BRINGING INDUSTRY THE NEWEST AND VERY BEST PRODUCTS

All the MoldStar® Alloys have been carefully developed & application tested to provide youwith the performance characteristics Performance Alloys is best known for. GUARANTEED!

The PERFORMANCE ALLOYS® & MoldStar® names mean BEST Quality, Availability, Value & Support..

Toll Free: 1-800-272-3031

Phone: 1-262-255-6662 Fax: 1-262-255-3655

E Mail: [email protected] Web Site: www.performancealloys.net

1-800-272-3031

Popular Mold Building Materials Specifications and Comparisons

Thermal

Conductivity at 680 FBtu/ft/hr/ft2/0F

Thermal Diffusivity

at 680 Fft2/hr

Brinell Hardness3,000 kg

Densitylbs/cu.in.

MoldStar® 150 (PAS 940) MoldStar® 90 MoldStar® 18 (PAS 18) MoldStar® 21 (PAS 21) MoldStar® 22 (PAS 22)

15090362525

2.321.76.97.62.62

210 (94Rb)311 (31Rc)192 (92Rb)286 (29Rc)331 (35Rc)

.315

.310

.269

.260

.255Aluminum QC7® 80 2.44 167 (500kg) .101 PROtherm® (Beryllium-0.5%) 145 2.32 157-210 (500kg) .319 moldMAX® (Beryllium 2.0%) 60 1.16 300-380 .297Tool Steel P20 20 0.39 265-345 .284Tool Steel H13 17 0.31 350-530 .284Stainless Steel 7 0.16 150-190 .284

Tensile Strengthksi

Yield Strengthksi

Compressive Strengthksi

Coefficient of Expansion in/in/0 F

x106

Elongation% in 2"

MoldStar® 150MoldStar® 90 MoldStar® 18MoldStar® 21MoldStar® 22

100150105110105

75140526062

80140386174

9.79.59.09.09.0

135141

0.5Aluminum QC7® 78 74 65 12.8 7

PROtherm®Beryllium 0.5% 110 90 90 9.8 10

moldMAX®Beryllium2.0% 175 150 150 9.7 7

Tool Steel P20 150 125 125 7.1 20

Tool Steel H13 250 200 225 6.1 15

Stainless Steel 82 36 80 6.5 69

MoldStar® 90Our NEWEST beryllium-free copper alloy for the blow moldingand injection molding industries as well as other Industrial Applications

After working closely with our customers in their demanding applications it becameobvious we needed to develop application specific alloys.

Performance Alloys has done exactly that!

Just like our service is focused to addressthe shortcomings of our competitors,MoldStar® alloys have been carefully developed to specifically address theshortcomings of competitive products.

In side by side applications, MoldStar® 90has shown measurable advantages overPROtherm®, moldMAX® & even MoldMATE®.

MoldStar ®90 available in ROUND Bar & PLATE Sizes

ROUND BAR from 3/8 " up to 3" Diameter *

PLATE SIZES from 1/2" up to 4" Thickness *

Call us to find out the sizes available for yournext application. Experience first hand thePerformance Alloys and MoldStar® difference.

IF NEEDED SEE WELDING SECTION FOR INFORMATION

1-800-272-3031 or 1-262-255-6662

Peformance Core Pins using MoldStar® Alloys

Materials for Cores for virtually any High Volume Mold Application

Excellent for Blow Mold Cavities

The accompanying table comparesthermal conductivity of MoldStar® 90 withother commonly used mold materials.

MoldMaterial

ThermalConductivity(Btu/hr/ft/0F)

MoldStar® 90 90

moldMAX ®

2% Beryllium60

Aluminum 90

Tool Steel(S7)

21

Tool Steel(P20)

20

Tool Steel(H13)

17

BERYLLIUM-FREE COPPER ALLOYSMoldStar® 90 FOR MOLD CORES / CAVITIESAS WELL AS OTHER APPLICATIONS

ROUND RODRound bar or plate, no

order is too small. We will cut to size anypiece of material.

DIAMETER(inches)

WEIGHT(pounds per foot)

NOMINALDIAMETER

DIAMETER(inches)


NOMINALDIAMETER

3/8

1/2

19/32

5/8

3/4

1

.482

.78

1.08

1.33

1.85

3.23

.394

.512

.59

.67

.78

1.024

1-1/8

1-1/2

2

2-1/2

3

Call for

4.14

7.5

14.1

19.5

29.5

information on

1.18

1.57

2.16

2.55

3.15

Sizes not shown

PLATE

THICKNESS(inches)

THICKNESSTOLERANCE

CHECK OUT 800-272-3031 or [email protected] INFO

1/21

21-1/

3

2

2-1/2

3-1/24

.56 -1.12 - 1.18

.5

2.12

3.12 - 3.15

- 2.16

9

1.55 - 1.57

2.53 - 2.55

3.55 - 3.62

CALL US AT

800-272-3031

OR VISIT

www. 4.1 - 4.13 performancealloys

.net

Need a size of Round Stock,Rectangle or Rings other than what ispublished? Give us a Call or Email us.

We are also your reliable source formilling, turning, conventional andwire & sinker EDM work, centerlessgrinding and blanchard grinding.

CLIFF MOBERG

MoldStar® 150 (PAS 940)the high-performance, beryllium-free copper alloy

for the blow molding and injection molding industries

Applications have proven MoldStar®150 as THE dependable material of choicefor blow molding and injection moldingapplications.

In many mold applications, theplacement of cooling passages isdictated by mold shape, size andcomplexity The excellent thermalconductivity of MoldStar® alloys helpcompensate for uneven wall thickness orpart configuration.

In a tested application, core temperaturesduring mold cycles ranged from120-1400F with tool steel components.The addition of MoldStar® inserts reducedtemperatures to 80-90 0F. In addition tolower temperatures, there was less of atemperature variation, resulting ingreater stability from cavity to cavity.

In addition to its superior thermal conductivity, MoldStar®150 offers the following advantages:

Accepts and maintains high surface finishes ●

Accepts etching and texturing.●

Offers welding compatibility with other copper alloys,tool steels and stainless steels to provide compositematerials for increased surface hardness in specificareas. SEE WELDING SECTION FOR INFORMATION

●

Requires no additional heat treatment. ●

Retains the inherent corrosion resistance of copper. Can be readily machined using conventional practicesas well as the electrical discharge method (EDM).

MoldStar®150 can be produced in various forms tocustomer requirements. In addition, the material isstocked in round rod, rectangular bar and plate.

MoldStar® core pins with standard tool steel sleeve

Mold cores for plastic overcaps of pressurizedcontainers

Blow mold for a PVC container

●

The accompanying table comparesthermal conductivity of MoldStar® 150 withother commonly used mold materials.

MoldMaterial

ThermalConductivity(Btu/hr/ft/0F)

MoldStar®150 150

PROtherm®

.5% Beryllium145

Aluminum 90

Tool Steel(S7)

21

Tool Steel(P20)

20

Tool Steel(H13)

17

BERYLLIUM-FREE COPPER ALLOYSMoldStar® 150 (PAS 940) FOR MOLD CORES / CAVITIES

AND OTHER APPLICATIONS

ROUND RODRound bar or plate, no

order is too small. We will cut to size anypiece of material.

DIAMETER(inches)


NOMINALDIAMETER

DIAMETER(inches)


NOMINALDIAMETER

1/43/8

15/321/2

19/325/83/47/81

1-1/81-1/41-3/81-1/2

.21

.44

.66

.841.051.281.822.272.973.764.665.626.69

.263

.385

.468

.532

.594

.658

.783

.8751.00

1.1251.2501.3751.500

1-3/42

2-1/42-1/22-3/4

33-1/83-1/43-1/23-5/8

44-1/25-1/8

9.1211.8915.0818.6122.5126.7929.0731.4836.4939.1347.6760.4878.23

1.7502.00

2.2502.5002.7503.00

3.1253.2503.5003.6254.00

4.5005.125

PLATE

THICKNESS(inches)

THICKNESSTOLERANCE

NOMINALTHICKNESS

1/23/41

1-1/22

2-1/23

3-1/24

+.038+.048+.060+.060+.060+.060+.060+.060+.060

.536

.7861.0361.5502.0502.5503.0503.5304.030

Need a size of Round Stock,Rectangle or Rings other than what ispublished?

NO PROBLEM! We can customforge pieces up to 3500 POUNDSwith lead times to meet your needs!

Need more than just a piece ofmaterial?

We are your reliable source formilling, turning, conventional andwire EDM work, centerlessgrinding and blanchard grinding.

MoldStar®18Continuous cast aluminum bronze rod/bar/tube

Description

A continuous cast aluminum-iron-copper alloy(UNS-95400) meeting the minimumrequirements of ASTM Standards. The excellentresistance of this alloy to wear and abrasionis available in continuous tube, round rod, andrectangular bar.

These characteristics make MoldStar®18 ideal forbushings, tie bar nuts, bearings, gears, wormgears, and similar applications.

Chemistry

Copper 85.5%Aluminum 10.5%Iron 3.5%

Mechanical Properties*

Proportional Limit (ksi) 18.5

Compressive Strength-Ultimate (ksi) .136

Fatigue Strength (ksi @ l08 cycles) 36

Impact -Charpy Keyhole (ft.-lbs.) 15

Izod (ft.-lbs.) 22

Modulus of elasticity (ksi) 16,000

Poissan's Ratio .316

*based on 1" dia. test barsToll Free: 1-800-272-3031 Fax: 1-262-255-3655 e-mail: [email protected]

Physical Properties

Density (lbs./in.3) .269

Specific Gravity 7.45

Specific Heat (Btu/lb./0F) .10

Coefficient of ThermalExpansion (in./in./0F)

9.0 x 10-6

Electrical Conductivity (%IACS)

13

Electrical Resistivity (Microhms-Meter @ 680F)

133

Thermal Conductivity (Btu/sq.ft./ft./hr./0F @ 680F)

34

Magnetic Permeability 1.3

Specifications

ASTMB148 C95400**B505 C95400

ASMESB148C95400**

FederalQQ-C 390C954 Type IIIas cast

MilitaryB-16033Amend 2, Class3

SAEJ462C95400B

CDA C95400

*Waive method of manufacture

MoldStar®18 Continuous cast aluminum bronze rod/bar/tube

Mechanical Properties

Moldstar®18Tensile Strength

ksiMin.

Yield Strengthksi

Min.

Elongation% in 2"

Min.85 32 12

Typical Applications include:

Wear Plates●

Gibs and Ways●

Gear Racks●

Wear Strips●

Support Rails●

Lifter Blades●

Guides●

Liners●

Keys●

Leader Pin Bushings●

Ejector Sleeves●

Hold-Down Bars●

Straightening Dies●

Lead Nuts for Unscrewing Molds●

MoldStar® 18Round Extruded Aluminum Bronze Rod

12 Foot Mill Lengths

Rectangular MoldStar® 18Aluminum Bronze Bar

UNS-C95400

MoldStar® 18Hollow Aluminum

Bronze Bar

MoldStar®18 (95400) MoldStar® 18

Round Extruded Aluminum Bronze Rod12 Foot Mill Lengths

NOMINALO.D.

APPROX.WT. NOMINAL

O.D.APPROX.

WT. NOMINALO.D.

APPROX.WT.

1/23/4

1022

3

3-1043-1/23-3/4

294344401456

55-1/45-1/25-3/4

8038819701067

11-1/41-4/21-5/81-3/4

35547587

101

22-1/42-1/22-3/4

133165207249

44-1/44-1/24-3/4

514586658733

66-1/46-1/2

114712351330

7 1538

8 2003

9 2569

Toll Free: 1-800-272-3031 Fax: 1-262-255-3655 e-mail: [email protected]

MoldStar®18 (95400) Rectangular MoldStar® 18

Aluminum Bronze BarUNS-C95400

THICKNESSIN

INCHES

WIDTHIN

INCHES

THICKNESSIN

INCHES

WIDTHIN

INCHES

THICKNESSIN

INCHES

WIDTHIN

INCHES

1/4X

11-1/41-1/2

22-1/2

346

12

5/8X

3456

1-1/4X

33-1/2

456

12

3/4x

3/41

1-1/21-3/4

22-1/2

33-1/2

45612

3/8x

11-1/2

22-1/2

33-1/2

456

12

1-1/2x

1-1/21-3/4

22-1/2

33-1/2

456

12

1/2x

11-1/41-1/21-3/4

22-1/2

33-1/2

4568

12

1x

11-1/41-1/21-3/4

22-1/2

33-1/2

45612

1-3/4x

22-1/2

3456

2x

22-1/2

33-1/2

456

5/8x

11-1/2

22-1/2

1-1/4x

1-1/41-1/21-3/4

22-1/2

2-1/2x

2-1/2345

3x 3

MoldStar®18 (95400)

The excellent resistance of Moldstar®18 alloy to wear and abrasion is available incontinuous-cast round and hollow bars. These characteristics make MoldStar® 18 ideal forbushings, tie-bar nuts, bearings, gears, worm wheels, and similar applications.

ChemicalComposition (%)

Copper 85.5

Aluminum 10.5

Iron 3.5

Other 0.5 (max.)

Weights in pounds Measures in inches

MoldStar® 18Hollow Aluminum

Bronze BarNOMINAL APPROX. NOMINAL APPROX.

I.D. O.D. WT. I.D. O.D. WT.

3/4x

1-1/41-1/21-3/4

2

396187

117

2-1/2x

33-1/43-1/23-3/4

44-1/2

56

110162224283343479631984

1x

1-1/21-3/4

22-1/42-1/2

3

4975

104138181270

2-3/4x

3-1/43-1/23-3/4

44-1/44-1/2

121182240307375444

1-1/4x

1-3/42

2-1/82-1/42-1/22-3/4

33-1/2

5988

105126166208253363

3x

3-1/23-3/4

44-1/44-1/2

55-1/2

67

1431992603273975567058971286


MoldStar®18 Hollow Aluminum Bronze Bar (continued)I.D. O.D. APPROX. WT. I.D. O.D. APPROX. WT.

1-1/2x

1-7/82

2-1/42-3/72-1/22-3/4

33-1/43-1/23-3/4

44-1/2

5167

101124145187233289341397462598

3-1/4x

3-3/14

4-1/44-1/2

5

150211231349495

3-1/2x

44-1/44-1/2

55-1/2

6

163281296445617795

1-3/4x

2-1/82-1/42-1/22-3/4

33-1/43-1/23-3/4

4

6078

119163209258319377438

3-3/4x 4-3/4 317

4x

4-1/24-3/4

55-1/2

678

18425833250268010801543

2x

2-3/82-1/22-3/42-7/8

33-1/43-1/23-3/4

44-1/2

56

7392

135157182230292349412546696

1036

4-1/4x 5 273

4-1/2x

55-1/45-1/2

661/2

209287376551761

5x

5-1/25-3/4

678

2243244098121277

2-1/4x

2-5/82-3/4

33-1/43-1/23-3/4

4

80103150198262313380

5-1/2x 6-1/2 448

6x 78

485949

6-1/2x 7-1/2 525

6-3/4x 7-3/4 5437x 8 561



MoldStar® 21extruded and continuous cast aluminum bronze rod and bar

Description

A wrought (UNS-C62500) or cast (UNS-C95900)aluminum-iron-copper alloy recommended forheavier-duty applications involving compressivewear and high abrasion, especially where no impactis present.

Uses include: die rings, forming rolls, inserts,wiping blocks, cam followers, pilot bushings, diesand drill jig bushings. Also, offers provenperformance in plastic mold applications - ejectorsleeves and bushings, guide pin and leader pinbushings, wear plates, gibs.

This alloy will maintain mechanical properties attemperatures up to 600 0F and has a machinabilityrating of 20%. The alloy provides corrosionresistance to non-oxidizing mineral acids. Can bewelded with both gas-shielded and shieldedmetal-arc processes. Brazing, soldering and oxyfuelgas welding are not recommended.

Cold working is not recommended. Hot formabilityis good with a forgeability rating of 75%. Thealloy can be hot worked at temperatures from 13750

to 15500F and annealed between 11000 and 12000F.

The consistent superiority of our alloys overcommercial bronze is due, in large part, to theunique distribution of alloy microstructure.

Chemistry

Copper 83%Aluminum 13%Iron 4%

Specifications

CDA C62500, C95900

Mechanical Properties(based on 1" test bars)

Tensile Strength (ksi) 110+

Yield Strength (ksi) 60+

Elongation, % in 2" .1+

Hardness- Rockwell C 29

Ultimate in Compression (ksi) 175

Proportional Limit (ksi) 34+

Impact - Charpy Keyhole (ft-lbs) 2

Izod (ft-lbs) 2

Modulus of Elasticity (tension), (ksi) 15,000

Poissan's Ratio .312

*Properties are shown for comparative information only

Physical Properties*Density (lbs/in3) .260

Specific Gravity 7.21

Specific Heat (Btu/lb 0F) .09

Coefficient of Thermal Expansion (in/in/0F) 9.0 x 10-6

Electrical Conductivity (% IACS) 10

Electrical Resistivity (Microhms-Meter @ 680F)

172

Thermal Conductivity (Btu/sq. ft./ft./hr./0F @ 680F)

22.5

Magnetic Permeability 1

MoldStar® 21 (95900) FOR THE MOLD INDUSTRY

Typical Applications include:Wear Plates●

Gibs and Ways●

Gear Racks●

Wear Strips●

Support Rails●

Lifter Blades●

Guides●

Liners●

Keys●

Leader Pin Bushings●

Ejector Sleeves●

Hold-Down Bars●

Straightening Dies●

Lead Nuts for Unscrewing Molds●

MoldStar® 21Round Extruded Aluminum

Bronze Rod12 Foot Mill Lengths

NominalSize Cast Size Lbs/In

11-1/2

1.0631.563

0.240.51

22-1/2

2.0632.563

0.891.37

33-1/2

3.0633.594

1.952.69

44-1/2

4.0944.625

3.494.45

56

5.1256.188

5.477.97

78

7.1888.188

10.7513.95

Continued

Rectangular MoldStar® 21Aluminum Bronze Bar

12 Foot Mill Lengths

Nominal Size Cast Size Lbs/In Nominal

Size Cast Size Lbs/In

1/4x

1 0.313 x 1.063 0.09

1x

1-1/4 1.063 x 1.313 0.36

1-1/4 0.313 x 1.313 0.11 1-1/2 1.063 x 1.563 0.43

1-1/2 0.313 x 1.563 0.13 1-3/4 1.063 x 1.813 0.50

2 0.313 x 2.063 0.17 2 1.063 x 2.063 0.57

2-1/2 0.313 x 2.563 0.21 2-1/2 1.063 x 2.563 0.71

3 0.313 x 3.063 0.25 3 1.063 x 3.063 0.85

4 0.313 x 4.063 0.33 3-1/2 1.063 x 3.563 0.98

3/8x

1 0.438 x 1.063 0.12 4 1.063 x 4.063 1.12

1-1/2 0.438 x 1.563 0.18 4-1/2 1.063 x 4.563 1.33

2 0.438 x 2.063 0.23 5 1.063 x 5.063 1.40

2-1/2 0.438 x 2.563 0.29 5-1/2 1.063 x 5.563 1.60

3 0.438 x 3.063 0.35 6 1.063 x 6.063 1.68

4 0.438 x 4.063 0.46

1-1/4x

1-1/4 1.313 x 1.313 0.41

5 0.438 x 5.063 0.60 1-1/2 1.313 x 1.5630.53

6 0.438 x 6.063 0.69 1-3/4 1.313 x 1.813 0.62

1/2x

1/2 0.563 x 0.563 0.08 2 1.313 x 2.063 0.70

1 0.563 x 1.063 0.16 2-1/2 1.313 x 2.563 0.87

1-1/2 0.563 x 1.563 0.23 3 1.313 x 3.063 1.06

1-3/4 0.563 x 1.813 0.27

2 0.563 x 2.063 0.30

1-1/2x

1-1/2 1.563 x 1.563 0.64

2-1/2 0.563 x 2.563 0.38 2 1.563 x 2.063 0.84

3 0.563 x 3.063 0.45 2-1/2 1.563 x 2.563 1.04

3-1/2 0.563 x 3.563 0.54 3 1.563 x 3.063 1.24

4 0.563 x 4.063 0.59 3-1/2 1.563 x 3.563 1.48

5 0.563 x 5.063 0.77 4 1.563 x 4.063 1.65

6 0.563 x 6.063 0.89 5 1.563 x 5.063 2.10

Rectangular MoldStar® 21 Aluminum Bronze Bar (continued)

5/8x

1 0.688 x 1.063 0.19

1-3/4x

1-3/4 1.813 x 1.813 0.88

1-1/2 0.688 x 1.563 0.28 2 1.813 x 2.063 0.98

0.688 x 2.063 0.37 2-1/2 1.813 x 2.563 1.22

2-1/2 0.688 x 2.563 0.46 3 1.813 x 3.063 1.46

3 0.688 x 3.063 0.55 3-1/2 1.813 x 3.563 1.72

3-1/2 0.688 x 3.563 0.66 4 1.813 x 4.063 1.96

4 0.688 x 4.063 0.73 5 1.813 x 5.063 2.44

6 0.688 x 6.063 1.08

2x

2 2.063 x 2.063 1.11

3/4x

3/4 0.813 x 0.813 0.17 2-1/2 2.063 x 2.563 1.38

1 0.813 x 1.063 0.22 3 2.063 x 3.063 1.64

1-1/2 0.813 x 1.563 0.33 4 2.063 x 4.063 2.18

1-3/4 0.813 x 1.813 0.38 5 2.063 x 5.063 2.72

2 0.813 x 2.063 0.44 6 2.063 x 6.063 3.25

2-1/2 0.813 x 2.563 0.54

2-1/2x

2-1/2 2.563 x 2.563 1.71

3 0.813 x 3.063 0.65 3 2.563 x 3.063 2.04

3-1/2 0.813 x 3.563 0.78 3-1/2 2.563 x 3.563 1.95

4 0.813 x 4.063 0.86 4 2.563 x 4.063 2.71

4-1/2 0.813 x 4.563 1.02 5 2.563 x 5.063 3.45

5 0.813 x 5.063 1.10

5-1/2 0.813 x 5.563 1.25

6 0.813 x 6.063 1.28

1x 1 1.063 x 1.063 0.29 3x 3 3.063 x 3.063 2.44

MoldStar® 22 ALUMINUM BRONZE

MoldStar® 22 is a harder alloy with good bearing qualities, resistance to wear,abrasion, fatigue, deformation and corrosion. This material is ideal for ejectorsleeves, lifter blades, thin wall applications, guide pin and leader pin bushings,and unscrewing mold components.

SOLID ROUNDSDiameter(inches)

Weight(lbs./ft.)

NominalDiameter

MoldStar® 22 Chemical Composition Copper 78.7%Aluminum 13.8%Iron 5.0%Other 2.5 %(max.)

Mechanical PropertiesThermal

Conductivityat 680F

Btu/ft/hr/ft2/0F

25Yield Strength

ksi62

ThermalDiffusivity

at 680Fft2/hr

.062Compressive

Strengthksi

74

Brinell hardness3,000kg

331(35Rc)

Coefficient ofExpansion

in/in/0F9.0

Tensile Strengthksi

105Elongation

% in 2".05

11-1/41-1/21-3/4

22-1/2

2.753.826.358.20

11.8616.56

1.061.251.611.832.202.60

3

Call us to1-800-272-3031

verify Stock Sizes

25.09 3.20

PERFORMANCE CORE PINS®.

PERFORMANCE CORE PINS® is one of the fastest growing products in the mold making industrytoday.

That is because PERFORMANCE CORE PINS® perform beyond our product claims in mostapplications. In addition to the unmatched performance, we offer superior quality with productavailability in more standard sizes than any conductivity pin on the market.

When it comes to cost, PERFORMANCE CORE PINS® provide one of the fastest returns on investmentpossible for any mold component used by the industry. Product cost is insignificant when you see theresults of quality and productivity improvement in your finished products.

When you use a PERFORMANCE CORE PIN® in place of a conventional steel core pin or berylliumcopper pin, without any other change to the mold, you will see improvement in the cooling of the plasticin the area affected by the pin.

This means faster cycles are possible, with higher quality parts, less scrap, less lost production. Theoverall results is more and higher profits.

Many mold makers and molders define "adequate cooling" as good water flow rates in close proximityto the molding surface. Many mold makers and molders are of the opinion that if the core pin or molddesign will not facilitate water directly in the pin, that there is no reasonable cooling opportunity. Manymolders don't believe they have a problem with heat transfer and cooling with their steel components.These mold makers and molders obviously haven't tried PERFORMANCE CORE PINS®.

Our product is made from a Beryllium-Free Copper Alloy that allow PERFORMANCE CORE PINS®

to transfer heat far better than standard steel core pins (6 -10 times), even better than MOLDMAX® brand ofberyllium-copper core pins (2 times)

QUALITY/MOLD CYCLE LIMITED BY CORE PINS

If you design, build or run molds that have any other core pin than a PERFORMANCE CORE PIN®,the piece part quality is not as good as what it could be and the mold is not performing to capacity. Try aPERFORMANCE CORE PIN® in your application, see the PERFORMANCE difference.

GLASS-FILLED RESIN APPLICATIONS

PERFORMANCE CORE PINS® can be titanium nitride (TiN) coated or chrome plated to provide wearresistance for abrasive filled resins. The TiN or chrome will provide the same additional wear life, as ifapplied to steel. And in certain abrasive resin applications without TiN, molders say that the pin lifecycle and replacement costs are substantially offset by the benefits of added cooling and the increase inmold productivity.

PIN FITS & SHUT OFFS

Many molders have found that by using PERFORMANCE CORE PINS®, they are able to run flash-freeparts, with more pin fit clearance and/or shut-off clearance, than would be allowable with conventionalsteel core pins.

PERFORMANCE CORE PINS® (Continued)

SLEEVE APPLICATIONS

Titanium Nitride (TiN) coating is recommended on a PERFORMANCE CORE PIN® in the sleevecontact area. Although uncoated PERFORMANCE CORE PINS® used in sleeve applications, haveworked well because of the reduced coefficiency of friction between the copper alloy pin and the steelsleeve. Sleeve and pin wear is always more prevalent in molds that are designed without "guided"ejector systems regardless of the core pin material. In unguided systems, pin life can be compromisedwithout the Titanium Nitride (TiN) coating.

PERFORMANCE CORE PINS®

10000 SERIES* Six times better conductivity thansteel

●

Two times better conductivity thatberyllium copper core pins

●

Made from MoldStar® 150 material●

Hardness 95-98 Rockwell "B"(20-25 Rockwell "C")

●

PERFORMANCE PINADVANTAGES

Higher tensile strength than P-20toolsteel

●

BERYLLIUM FREE ●

Retains the inherent corrosionresistance of copper

●

Provides control over cycle times ●

Reduces post-mold shrinkageproblems

●

Requires no additional heattreatment

●

Suitable for service in ejectorsleeves while providing dissimilarmetal and compatible coefficientof friction to reduce metal to metalpick up and wear

●

Tens of thousands of successfulapplications

●

TOLERANCESPin Diameter(A)

+.001-.000

Head Thickness(T)

+.000-.002

Head Diameter(H)

-.000-.010 Length (L) +.375

-.00

Available in lengths of 3", 6", 14", 20"-Specify (L)See Price List for Standard Sizes/PricesOther Sizes available upon request.

SPECIFICATIONSCP10000

Series"A"

Pin Dia."H"

Head Dia."T"

Head Thick.

10093 3/32 1/4 1/8

10109 7/64 1/4 1/8

10125 1/8 1/4 1/8

10140 9/64 1/4 1/8

10156 5/32 9/32 5/32

10171 11/64 11/32 3/16

10187 3/16 3/8 3/16

10203 13/64 3/8 3/16

10218 7/32 13/32 3/16

10250 1/4 7/16 3/16

10281 9/32 7/16 1/4

10312 5/16 1/2 1/4

10343 11/32 9/16 1/4

10375 3/8 5/8 1/4

10406 13/32 11/16 1/4

10437 7/16 11/16 1/4

10468 15/32 3/4 1/4

10500 1/2 3/4 1/4

10562 9/16 13/16 1/4

10625 5/8 7/8 1/4

10750 3/4 1" 1/4

WHEN ORDERING SPECIFY QUANTITY, CATALOGNUMBER, and "L" DIMENSION

*Performance Core Pins® are produced under U.S. Patent, #5,020,770

High Conductivity Core Pins

PRICE LIST (*POR notes Price by Request for non stock) CP 10000

Series 3" 6" 14" 20"

10093 13.95 15.55 22.20 POR

10109 POR POR POR POR

10125 12.88 14.50 20.56 29.85


10156 13.78 15.38 21.76 31.57

10171 13.12 15.38 21.76 POR

10187 13.28 15.38 21.09 30.62

10203 13.29 15.38 21.07 POR

10218 15.06 17.33 25.46 36.73

10250 14.68 17.33 25.46 35.96

10281 13.95 17.33 25.46 POR

10312 14.08 17.33 25.46 34.82

10343 17.04 22.26 31.99 POR

10375 17.33 22.26 32.39 46.83

10406 21.26 25.67 41.61 POR

10437 21.26 25.67 41.61 POR


10500 20.88 25.29 41.08 POR

10562 24.15 30.33 51.18 POR

10625 23.42 29.61 50.17 POR

10750 25.71 33.77 59.06 POR


PERFORMANCE SPRUE BUSHINGS® are recommended by a variety of resin manufacturers,molders, mold makers, designers and engineers as a product that works, is truly a straightforward,uncomplicated processing aide.

The PERFORMANCE SPRUE BUSHING® is available in a number of popular standard sizes, with nonstandards offered at reasonable prices with quick deliveries.

Many users are so pleased with the overall performance of this product that the PERFORMANCESPRUE BUSHING® is now specified in all of the molds they build.

Try one, you will not be disappointed.

Prices on standards are between $243.00 - $271.00 (Carbide-lined slightly higher.)We can also supply with a "wire start" hole only for customer finished internal detail

CYCLE TIMES LIMITED BY SPRUE

Mold cycles are often limited or controlled by the length of time needed for the solidification of theplastic sprue. The sprue must be cool enough not to break or tear as the mold is opened. Or, whenmolding small parts where the parts could be ejected, but the sprue is not solid enough to allow moldopening, there is added time just for sprue cooling. These cycle limiting conditions can be changed by using the Performance Sprue Bushing®, without any other changes to the mold.

CORROSION & STICKING SPRUES

Many plastic resins, additives, colorants and combinations lead to corrosion and sticking problems withconventional steel sprue bushings. The inherent corrosion resistance and release properties of the copperalloy used in the Performance Sprue Bushing® offers a significant increase in performance and productlife compared to conventional steel sprue bushings.

SPRUES AS ROBOT GRAB POINTS

The sprue is often used as the grab point in robotic removal of parts, sprues and runners. This requiresthat the sprue be rigid enough to resist the pressure of the robot fingers as well as the extraction forces.With conventional steel sprues this measure is most often met by added cooling time to the mold cycle.The Performance Sprue Bushing® will again reduce the sprue cool time, without any other changes tothe mold. Use of this product will yield more rigid sprues with reduced cool times set on the moldingmachine timer.

PREVENTING MOLDING PROBLEMS CAUSED BY SPRUES

Molders that use Performance Sprue Bushings® in a variety of mold and resin applications say they areable to control many sprue related problems. They no longer "just struggle with sprue problems".

CALL US WITH YOUR APPLICATION TODAY TOLL FREE 1-800-272-3031

PERFORMANCE Sprue Bushings®

PERFORMANCE SPRUE BUSHING®

ADVANTAGES

Beryllium-Free Copper Alloy body for fast HeatTransfer

●

Stainless Steel Nozzle Seat for wear resistance andto insulate nozzle heat

●

Reduced cycle time due to faster sprue cooling rates ●

Rigid sprues for improved targets for sprue pickers●

Eliminate "sticking sprues" due to inherent releaseproperties of copper alloys

●

Quality and productivity improvement due toconsistency and repeatability of operation

●

Highly corrosion resistant to resins such as PVC &Others

●

Reduce scrap caused by product/hot sprue contact onconveyor or in drop boxes

●

Recognized by Eastman as an advantage inprocessing their resin

●

U.S. Patent Number 4,950,154●

Made of MoldStar®150 material (Beryllium-free) withhardened 420 S.S. insert at nozzle seat area.

SPECIFICATIONSPB SERIES"D"=1,000

Diameter Shank"A" "L"

PB 6602 129/32 225/32

PB 6604 229/32 325/32

PB 6606 329/32 425/32

PB 6608 429/32 525/32

PC SERIES"D"=.750Diameter

Shank

"A" "L"

PC 6602 129/32 225/32

PC 6604 229/32 325/32

PC 6606 329/32 425/32

PC 6608 429/32 525/32

Available in "O"- 5/32 ,7/32, or 9/32Available in "R" 1/2 or 3/4

OTHER SIZES AVAILABLE ONREQUEST

PRICE AND DELIVERY ONREQUEST

PERFORMANCE Sprue Bushings®

with Tungsten Carbide channel to RESIST WEARADVANTAGES

CARBIDE-LINED sprue channel, 77-80 R/C for Wear &Corrosion Resistance and Heat Transfer

●

Beryllium-Free Copper Alloy body for super-fastHeat Transfer

●

Hardened stainless steel nozzle seat as an insulatingfeature

●

Reduces Mold Cycles due to Faster Sprue Cure Rates●

More rigid sprue for improved targets for roboticsprue pickers

●

Stop sprue from sticking to robot fingers ●

Reduce product loss/damage due to contact with hotsprue

●

Reduce mold maintenance costs due to extendedsprue life

●

Runner/Part features in carbide insert must be wire orconventionally EDM'd

●

Some applications may require hardened ringinterface at end of bushing

●

MoldStar®150 material (Beryllium free) body, with hardened420 S.S. insert at nozzle seat area, Carbide-lined sprue channel

Manufactured under U.S. Patent 5,925,386

For ABRASIVE RESINS

SPECIFICATIONSPB SERIES

"D"=1,000 DiameterShank

"A" "L"

PB 6602 C 129/32 225/32

PB 6604 C 229/32 325/32

PB 6606 C 329/32 425/32

PB 6608 C 429/32 525/32

PC SERIES"D"=.750

Diameter Shank"A" "L"

PC 6602 C 129/32 225/32

PC 6604 C 229/32 325/32

PC 6606 C 329/32 425/32

PC 6608 C 429/32 525/32

Available in "O"- 5/32 ,7/32, or 9/32Available in "R" 1/2 or 3/4

OTHER SIZES AVAILABLE ONREQUEST

PRICE AND DELIVERY ONREQUEST

You can also submit orders Online @www.performancealloys.net

PERFORMANCE ALLOYS & SERVICES, INC.N116 W18515 Morse Drive

Germantown, WI 53022(262) 255-66621-800-272-3031

Fax (262) 255-3655REQUESTED SHIPPING:

NEXT DAY 2ND DAY REGULAR OTHER_______________

QUOTE ORDER NEW ACCOUNT EXISTING ACCOUNT

MSDS YES NO CERTS. YES NO

Contact Your P.O. No.

Phone Quote Date

Fax Requested Ship Date

Sold To Ship To Referred By

Company Company

Address Address

"P"=PLATE "B"=BAR "F"=FORGING

Qty Grade Size (we cut oversize to finish to) Est.Wt.

1

2

3

4

5

6

7

SPECIAL NOTES (include your drawings and/or specifications where applicable)

Custom Orders

Dissatisfied with your current manufacturer? Or first considering outsourcing your finished machinecores, sleeves, cavity bushings or other mold components?

Look to Performance Mold Products for unmatched quality, competitiveprices, and on time deliveries.

Performance Mold Products supplies many molders and moldmakers with finished machinecomponents. We help molders and mold makers better utilize their shop and their technical people, to dowhat they do best. Simply by doing what we do best, making high quality mold components.

If you really need it in a hurry, though we can't get it done for you by yesterday, we may surprise you bysaying the we can get it done for you today, tomorrow or in a week if you need it.

Our affiliation with a raw material supplier and our manufacturing capabilities for standard productsputs Performance Mold Products in a unique position. We have immediate access to a variety of rawmaterials. And we even may have a machine or component in some stage of process where we canquickly respond to your needs.

Consistently, year after year, we are rated at the highest levels for Quality,Service, Competitive Prices and on-Time Deliveries by our customers.New to outsourcing finished machine components? We will make that experience trouble free.I personally invite you to give us the opportunity to show you our level of quality and service.For Orders, Quotations you may:

Submit an Order, Pricing Request or Technical Support Online: www.performancealloys.net●

Call us directly at 1-800-272-3031●

Or fax us at 262-255-3655●

Cliff Moberg Performance Mold Products, Vice President Performance Alloys, President

http://www.g-web.net/Alloys/order.html

Hardened &Nitrided H-13 Ejector PinsCAT NO.

PIN.DIA.

HEADDIA.

HEADTHICK

CAT.NO.

PIN.DIA.

HEADDIA.

HEADTHICK

PX3 1/32 1/4 1/8 PX22 21/64 9/16 1/4PX4 3/64 1/4 1/8 PX23 11/32 17/32 1/4PX5 1/16 1/4 1/8 PX24 23/64 35/64 1/4PX6 5/64 1/4 1/8 PX25 3/8 5/8 1/4PX7 3/32 1/4 1/8 PX26 25/64 5/8 1/4PX8 7/64 1/4 1/8 PX27 13/32 19/32 1/4PX9 1/8 1/4 1/8 PX28 27/64 39/64 1/4

PX10 9/64 1/4 1/8 PX29 7/16 5/8 1/4PX11 5/32 9/32 5/32 PX30 29/64 45/64 1/4PX12 11/64 11/32 3/16 PX31 15/32 23/32 1/4PX13 3/16 3/8 3/16 PX32 31/64 3/4 1/4PX14 13/64 3/8 3/16 PX33 1/2 3/4 1/4PX15 7/32 13/32 3/16 PX35 17/32 3/4 1/4PX16 15/64 27/64 3/16 PX37 9/16 13/16 1/4PX17 1/4 7/16 3/16 PX41 5/8 7/8 1/4PX18 17/64 7/16 1/4 PX45 11/16 15/16 1/4PX19 9/32 15/32 1/4 PX49 38/4 1" 1/4PX20 19/64 1/2 1/4 PX57 7/8 1-1/8 1/4PX21 5/16 1/2 1/4 PX65 1" 1-1/4 1/4

PDM Standard StraightType Ejector Pins

TOLERANCED - PIN DIA.H - HEAD DIA.T - HEAD THICK.L - OVERALL LENGTH

+.000-.001+.000-.010+.000-.002+1/32-.000

NOTE: When ordering, specify Catalog No.and length, or pin diameter and length.

Non-Standard sizes available on Request

Long Pins available (over 18") made to order

PDM Ejector Pins

PDM Standard StepType Ejector Pins

CAT.NO.

PINDIA.

D

HEADDIA.

H

HEADTHICK.

T

SHANKLGTH.

S

OVER-ALL

LGTH

CAT.NO.

PINDIA.

D

HEADDIA.

H

HEADTHICK.

T

SHANKLGTH.

S

OVER-ALL

LGTHMX 1/26-3 1/32 1/4 1/8

1/2

6 MX210-8 7/64 1/4 1/8 2 10MX 1/26-4 3/64 1/4 1/8 6 MX 48-3 1/32 1/4 1/8

4

8MX 1/26-5 1/16 1/4 1/8 6 MX 48-4 3/64 1/4 1/8 8MX 1/26-6 5/64 1/4 1/8 6 MX 48-5 1/16 1/4 1/8 8MX 1/26-7 3/32 1/4 1/8 6 MX 48-6 5/64 1/4 1/8 8MX 1/26-8 7/64 1/4 1/8 6 MX 48-7 3/32 1/4 1/8 8MX 26-3 1/32 1/4 1/8

2

6 MX 48-8 7/64 1/4 1/8 8MX 26-4 3/64 1/4 1/8 6 MX 610-4 3/64 1/4 1/8

610

MX 26-5 1/16 1/4 1/8 6 MX 610-5 1/16 1/4 1/8 10MX 26-6 5/64 1/4 1/8 6 MX 610-6 5/64 1/4 1/8 10MX 26-7 3/32 1/4 1/8 6 MX 610-7 3/32 1/4 1/8 10MX 26-8 7/64 1/4 1/8 6 MX 610-8 7/64 1/4 1/8 10MX 28-3 1/32 1/4 1/8 8 MX 812-4 3/64 1/4 1/8

812

MX 28-4 3/64 1/4 1/8 8 MX 812-5 1/16 1/4 1/8 12MX 28-5 1/16 1/4 1/8 8 MX 812-6 5/64 1/4 1/8 12MX 28-6 5/64 1/4 1/8 8 MX 812-7 3/32 1/4 1/8 12MX 28-7 3/32 1/4 1/8 8 MX 812-8 7/64 1/4 1/8 12MX 28-8 7/64 1/4 1/8 8 MX 1014-4 3/64 1/4 1/8

1014

MX 210-4 3/64 1/4 1/8 10 MX 1014-5 1/16 1/4 1/8 14MX 210-5 1/16 1/4 1/8 10 MX 1014-6 5/64 1/4 1/8 14MX 210-6 5/64 1/4 1/8 10 MX 1014-7 3/32 1/4 1/8 14MX 210-7 3/32 1/4 1/8 10 MX 1014-8 7/64 1/4 1/8 14

Custom Order FormName:

Company Name:

Billing Address: Shipping Address:

City: City:

State: State:

Zip/Postal Code: Zip/Postal Code:

Day Phone: Fax Number:

E-Mail: Date Required by:

Conventional Ejector Sleeve

Dimensions

B1 K

B2 L

G M

H

Quantity

Material H 13 Other

Other Material

Hardness (Rc)

Nitride O.D. I.D.

Tolerances*

Comments

Ejector Sleeve Tolerances*

Sleeve/Shoulder Dia.(G/D) +.000-.001

Head Diameter (H) +.000-.010

Head thickness (K) +.000-.002

Sleeve I.D. (B) +.0005-.0000

Length (M) +.12-.00

*Standard tolerances unless otherwise noted

Fax To: 262-255-3655 or complete On-Line @ our website: www.performancealloys.net

Custom Step Pin

Dimensions

D L

G M

H R

K

Quantity

Material H 13 Other

Other Material

Hardness (Rc)

Nitride Yes No

Tolerances*

Comments

Core Pin Tolerances*

Pin Diameter (G) +.001- .000

Head Diameter (H) +.000- .010

Head Thickness (K) +.000- .002

Length (M) +.375- .00


Fax to: 262-255-3655 or complete these forms Online @ our website: www.performancealloys.net

Ejector Pin Tolerances*

Pin Diameter (G) + .000- .001

Head Diamerter (H) + .000- .010

Head Thickness (K) +.000- .002

Length (M) +.375- .00


Conventional Pin

Dimensions

G K

H M

Quantity

Material H 13 Other

Other Material

Hardness (Rc)

Nitride Yes No

Tolerances*

Comments

Order Specifications

WELDING GUIDELINES for MoldStar®150 & MoldStar®90Feedback from material users that have welded MoldStar® 150 and MoldStar® 90 indicate that Tigwelding with Argon as the preferred shielding gas for Tool and Die type welding.

Brazing, gas welding and silver soldering are not recommended and did not show much success orpromise.

Small parts do not need to be preheated, other than to warm the part enough to dry them ofenvironmental humidity.

Larger blocks should be preheated to between 400 and 500 degrees F. This procedure is done primarilyas a measure to keep the block itself from being a heat sink. If this measure is not taken, the coolermass of the block will pull heat needed to melt away from the area of concentration.

During preheating procedures, blocks should not be left in room air at elevated temperatures longerthan actually needed to elevate to desired temperature. If blocks are left to preheat for excessiveperiods of time, copper oxides will form on surfaces which is potential contamination to weld area.If oxides form they should be cleaned from the immediate weld area, prior to welding procedure, witha wire brush or other non-destructive cleaning method.

WELDROD: to be used for repair is our MoldStar® weld wire.

Available from us in 1/16 diameter x 36" bare wire electrode and also .047 diameter as coil stock bothsizes are sold per pound. MoldStar® weld rod available Exclusively from Performance Alloys.(Approx 20 pieces of 1/16 wire to the pound)

Our NEW MoldStar® weldrod has shown to be the rod of choice to repair all MoldStar® alloys,Copper Nickel alloys, and Beryllium Copper alloys. HARDNESS level is reasonably close to parentmaterial where applied,

Great COLOR MATCH with no sink at edges of weld zone.

Alternate welded materials:• 420 Stainless, for high hardness• 17-4PH Stainless, for hardness

Weld Sample Shown below Courtesy of Five Star Tool Welding, Butler, Wisconsin, 262-783-5822,

MoldStar® is a registered Trademark of Performance Alloys and Services, Inc.

Performance Alloys and Services, Inc.1-800-272-3031 or 262-255-6662

Fax: 262-255-3655Email: [email protected]

Mold ®

NEW FOR WELD REPAIR OF COPPER BASED ALLOYS

Weld Wire

For WELDING ALL COPPER ALLOYS USED IN MOLD APPLICATIONSSPECIFICALLY: MoldStar® 150, MoldStar® 90, C18000, Ampco® 940 &MoldMATE® 90 as well as Brush Wellman’s moldMAX® LH & HH, also PROtherm®,and other BeCu alloys.

MoldStar® Weld Wire is a BRANDNEW product developed byPerformance Alloys for use by tool anddie/mold welders.MoldStar® Weld Wire is high purityand alloyed specifically for repairing orrestoring surfaces, edges, corners andareas that have been machined ordamaged outside of acceptable limits.This product is Beryllium-Free but canbe used to weld Beryllium copperalloys, with the same outstandingresults as seen when used on MoldStaralloys.

Performance Alloys and Services, Inc.1-800-272-3031 or 262-255-6662

Fax: 262-255-3655Email: [email protected]

• Excellent Color Match with bothCopper Nickel & BerylliumCopper Alloys

• Hardness AS APPLIED is within2-4 to Rockwell “C” points ofParent Material applied to.

• Beryllium-Free• Available in 1/16 X 36” Bare Wire

Electrode & .042 Coil Stock• Approx. 20 pieces 1/16 per Pound

Please have your TOOL WELDERContact US for MoldStar® Weldwire

MO

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Copper Beryllium Vs.Beryllium-Free CopperLearning the advantages and disadvantages of each alloy coupled with adhering to safety measures can help your shop stay safe.

Sherry L. Baranek

Both copper beryllium and beryllium-free copper producers are vehementand adamant about why their

products are better and safer than the othersout there — and between MSDSs,newspaper articles and media hype,separating fact and fiction can be aconfusing and time-consuming venture.Representatives from both sides of thefence weigh in on the pros and cons of eachalloy so you can make the right decisionabout what is best for your shop.

Beryllium — a silver-gray metallicelement that occurs naturally in about 30minerals — is lighter than aluminum yetstiffer than steel. For the moldmaker, thistranslates into efficient heat conduction andfaster cooling. However, this element canbe hazardous to your health. According tothe Department of Energy (DOE) TrainingReference for Beryllium Workers andManagers/Supervisors Participant Manualentitled Communicating Health Risks,Working Safely With Beryllium, the mostsignificant disadvantage of beryllium as anindustrial material is the toxicity of its dust,fumes and soluble salts. And, unless venti-lation and other controls are used, smallparticles and chips of insoluble beryllium-containing materials break off duringmachining and other processes and spreadthrough the air in the work area.

Inhalation of these tiny particles is thetype of exposure that can lead to chronicberyllium disease (CBD) — anirreversible and sometimes fatal scarringof the lungs (see Warning Signs ofChronic Beryllium Disease). On the otherhand, all of the documented cases of CBDthus far have dealt with the element in itspure form — either as pure beryllium orpure beryllium compounds — and onceberyllium is dissolved into copper,beryllium comprises about 1.85 percent ofthe alloy.

Non-beryllium copper alloys —developed as an alternative to copperberyllium — contain nickel, which also is onthe same list of hazardous substances.However, non-beryllium alloy manufacturerspoint out that nickel is only a carcinogen infish, and when nickel is machined andground, the particles do not become airborne,as is the case with beryllium.

So, what is a moldmaker to do whenconfronted with such a difference ofopinion on such a controversial topic?Who is right and who is wrong? How canyou be sure that the information out thereis accurate? Unfortunately, there is notenough evidence at this time to provideyou with the “right” answer — but you cantake a closer look at both sides of the storyto make a more educated decision.

Copper BerylliumNate Gildersleeve, director of technology

for NGK Metals Corp. (Reading, PA) — amanufacturer of copper beryllium products— urges people to be cautious when dealingwith copper beryllium, but not to panic. “Asa rule, anything that is published — partic-ularly by manufacturers of competitivealloys — does not distinguish betweenhandling pure beryllium and something thatcontains less than one percent of beryllium.People just see that name beryllium and it isdealt with categorically. Even we actuallydon’t make as much discrimination as isdeserved between pure beryllium and aberyllium-containing alloy because wewant people to treat it with respect.

“The unfortunate effect — based onwhat’s been published and what thecompetitive material manufacturers put outthere — is that respect has been replacedby fear,” Gildersleeve continues. “It’s verycounterproductive for us. This is the heartof the subject, yet it’s appropriate to keeppeople grounded in caution — they

shouldn’t grind half of the material awayand just let it get into the air because theremay be one of those unlucky couplepercent of people with ‘right’ allergy thatwill cause them to contract CBD. We stillhave to be responsible about it, but we arealways looking for an appropriate way toimprove people’s understanding aboutwhat the risks are and where they comefrom, and what’s the magnitude comparedto what they are reading about. It’s hard toseparate from all of this when the wordberyllium is in your name.”

Carlos Cruz Wilson, a metals specialistfor Houston, TX-based National Bronzeand Metals, Inc. — a producer and distrib-utor of a range of copper and copper alloysin various forms and shapes — also feels

Shop Talk

Recently MoldMaking Technologymagazine conducted an online poll todiscover which alloy was more prevalentin the shop. Forty-three percent of therespondents reported that they use bothcopper beryllium and beryllium-freecopper alloys, 43 percent only useberyllium-free copper alloys, and 14percent use copper beryllium exclusively.

Copper beryllium alloy users citedbetter cooling properties and heattransfer qualities as the main reasonsthat they use these alloys. One respon-dent felt that “copper beryllium is harderand stands up to the rigors of moldingbetter.” Users of beryllium-free copperalloys noted safety and health concernsover copper beryllium as the reasonthey choose beryllium free. Severalrespondents also felt that they achievedthe same performance with beryllium-free copper “without the problems.”

the public outcry over copper beryllium ismainly caused by ignorance. “The healthissues, although legitimate, can becontrolled with the proper handling of theberyllium alloys, or even the berylliummetal itself,” he states. “Only whenberyllium-containing materials are ground,sanded, polished, welded, EDM’d orchanged — producing a dust, fume or mist— will there be any risk of exposure.Turning, milling and drilling presentlycreate no risk when done wet with theproper coolant.

“Only when these airborne particles areless than 10 microns in diameter are they ableto penetrate the air sacs of the lungs, thuscausing a high risk situation,” Wilsoncontinues. “For beryllium to cause disease,the particles must penetrate the air sacs of thelungs with repeated exposure. The personexposed also needs to be allergic to berylliumto get the disease, and statistics show that onlyabout three to four percent of the population issusceptible to the effects of beryllium.”

Wilson adds that beryllium’s uniqueproperties “give copper the strength ofsteel, with the conductivity of a copperalloy,” and allow the moldmaker to bringheat energy into the old and dissipate thatenergy very quickly. “The results areshorter cycle times, which leads to theability to produce more parts and put moremoney in your pocket,” he affirms.

NGK Metals mandates that first-timebuyers of its copper beryllium read theMSDSs and Speaking Out literature thatdescribe the risks of working with the alloyand how these risks are managed. “In anutshell, if you are set up to safely machinemetals, you also can safely machineberyllium copper,” Gildersleeve states.“There isn’t a lot of dry grinding that goeson out there for making a finished machinepart, or the kinds of operations that put fineparticles into the air. We do cautionmoldmakers against torch cutting pieces —to cut into larger pieces they should be usinga saw. We make precautionary statementsand we are liable and required to put somevery stringent warning labels on the materialas well to protect against misuse.

“The non equitable facet to this that’salways amazed me is that there have beenarguments for some time about how tocharacterize the health hazards ofberyllium and what levels are appropriateand so forth; and most of the competitivealloys contain nickel — which has been aknown carcinogen for a long time — andthere’s just no fuss made about that forsome reason,” Gildersleeve adds. “I mean,

it’s in your flatware, stainless steel, etc.,and the copper alloys that compete withberyllium copper contain higher levels ofnickel, but for whatever reason it justdoesn’t seem to get much attention.”

Cliff Moberg, president of PerformanceAlloys (Germantown, WI) — a supplier ofberyllium-free copper alloys for use inconstructing cavities, cores and inserts, aswell as other applications — refutes theaforementioned statement. “While nickelis a listed carcinogen, the human exposuremethods vastly differ for the elementsberyllium and nickel,” he explains. “Therisk to humans with nickel is throughingestion of contaminated fish andseafood caught from nickel-contaminatedwaters. Those contamination arenas werecommon in the days of industrial wastedumping prevalent in years past.Additionally, since nickel is a heavymetal, the particles do not becomeairborne like beryllium,” he points out,“and there is no known direct connectionto human disease with inhalation ofnickel, where there is with beryllium.”

Beryllium-Free CopperAccording to Moberg, his company’s

copper nickel alloys possess the same

superior strength and conductivity ofcopper beryllium, if not better. “In addition,we have found that copper berylliumproducts are sensitive to heat,” hecomments. “In other words, some copperberyllium alloys lose hardness, tensile andconductivity if it is heated above 600°F,where our product is unaffected to temper-atures in excess of 900°F.”

Moberg also contends that copperberyllium producers use a number oftactics to steer potential users toward theirproduct and mask the alloy’s contents thatcould be termed questionable. “The mostobvious example is that they publishcopper beryllium’s ultimate propertiesinstead of the average numbers to comparetheir products,” he says. “Our competitorspublish their numbers on a higher scalewhile we publish our nominal numbers —taking their very best properties andpublishing them instead of publishing thetypical mean (most often attainable)numbers that we do. It would be nice ifthey would note that they were publishingtheir ultimate properties. We note in ourliterature that our numbers are nominal. Ifyou are comparing products, make surethat the information you are looking at iseither third-party based or it’s objective

CBD is primarily a lung disease, although it can affect other organs — likethe lymph nodes, skin, spleen, liver, kidneys and heart. It occurs in individ-uals who are “allergic” or sensitized to beryllium upon exposure. The long-term health effects can take years to develop after the first exposure toberyllium and there have been cases where people who were exposed tovery small amounts of beryllium contracted CBD.

Symptoms of CBD may include the following:➥ Persistent coughing.➥ Fatigue.➥ Shortness of breath with physical exertion.➥ Blood in saliva and mucus that is coughed up.➥ Chest and joint pain.➥ Loss of appetite.➥ Rapid heart rate.➥ Fevers and night sweats.

If you are experiencing any of these symptoms contact your physician.

— From Communicating Health Risks, Working Safely With Beryllium(published by DOE).

Warning Signs of Chronic Beryllium Disease (CBD)

reporting — not something provided fromthe producer of the product.”

To that statement NGK Metals’Gildersleeve responds, “Among berylliumcopper producers, there may be somevariations in how the product is presentedin promotional literature,” he comments.“It appears to me that beryllium copperproducts are represented nominally, ratherthan the highest possibility, includingpromotions published by our direct compe-tition (i.e., beryllium copper producers).For instance, a possible hardness range forone product may be 36 to 42. The medianis 39, but the product may be nominallyadvertised at 40. I do not cry foul againstour competitor because their product (andours) is statistically better represented by40 than by 38 or 42 after testing hundredsof pieces.”

Moberg of Performance Alloys adds thatrecent independent testing conducted atWestern Michigan University proves thatberyllium-free alloys perform from a cycletime standpoint about five to seven percentbetter than any of the beryllium copper

alloys that were tested. According to thisstudy — which compared widely usedmold steels with beryllium copper andberyllium-free copper alloys and focusedon cycle time reduction, quality changesand component performance — theberyllium-free alloy performed sevenpercent faster than the beryllium copperalloys.

Making a ChoiceNGK Metals’ Gildersleeve does his best

to simplify this complicated issue. “Itreally boils down to whether the partmanufacturer is designing the tool, or amachine shop or subcontractor is designingthe tool,” he states. “If your job is to makemoney by making more parts that you canship at the end of the day, then berylliumcopper will give you a way to do that. Thatis our experience. When we see peopledesigning molds whose primary source ofrevenue comes from making parts, there’sberyllium copper all over their molds. Iftheir primary source of revenue is makingmolds, beryllium copper is usually

relegated to occasional insert materialswhere just nothing else will work.”

As the popular saying goes, “Forewarnedis forearmed.” Before you make a decisionabout which alloy to use, educate yourself.Your alloy manufacturers and suppliershave guidelines for safe machining,EDM’ing and polishing. Go to theirwebsites and read the MSDSs. The infor-mation is out there and readily available —it is up to you to get your hands on it andabsorb it before you can decide what worksfor your shop. Gildersleeve sums it up quitenicely, “Whether you are using a beryllium-containing alloy or a non-beryllium-containing alloy, don’t use either as alicense to lower your guard about healthand hygiene.”

MMT

For more information contact CarlosCruz Wilson of National Bronze & Metals,Inc. (Houston, TX) at (713) 869-9600, NateGildersleeve of NGK Metals Corp.(Reading, PA) at (610) 921-5026 and CliffMoberg of Performance Alloys (German-town, WI) at (262) 255-6662.

©2002 Communication Technologies, Inc., All Rights Reserved.Reprinted from MoldMaking Technology magazine. Contents cannot be reprinted without permission from the publisher.

www.moldmakingtechnology.com

http://www.moldmakingtechnology.com

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